Bearing assembly of a motor shaft of an electric motor

ABSTRACT

A bearing assembly for a motor shaft of an electric motor having a stator. The stator is formed by a stator core having a plurality of stator laminations, which are stacked one on the other. The stator core has a first outer partial stator core, a second outer partial stator core, and a central partial stator core. The central partial stator core is arranged between the two outer partial stator cores. A continuous opening is arranged in each of the partial stator cores, in which openings bearings for supporting the motor shaft are arranged and the motor shaft is arranged. A diameter of the opening of the central partial stator core is smaller than a diameter of the opening of the outer partial stator cores such that a diameter transition from the central partial stator core to an outer partial stator core forms an axial stop for a bearing.

This nonprovisional application is a continuation of InternationalApplication No. PCT/EP2017/056316, which was filed on Mar. 16, 2017, andwhich claims priority to German Patent Application No. 10 2016 205252.7, which was filed in Germany on Mar. 30, 2016, and which are bothherein incorporated by reference.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a bearing assembly for a motor shaft ofan electric motor, in particular an electric motor for a fan of a heatexchanger or for a blower of an air-conditioning system, in particularof a motor vehicle.

Description of the Background Art

Known electric motors have a stator made up of a laminated core, aroundwhich a winding is usually disposed. In addition, a central opening,through which the motor shaft of the electric motor protrudes, isprovided in the stator. The motor shaft is also usually supported insuch a way that it is able to continuously carry out the rotationalmovements in a stable position.

DE 200 21 796 U1 discloses an electric motor having a stator which isformed from a laminated core. In this laminated core, a centrallydisposed, through-engaging opening, with which a sleeve engages, isdisposed in this laminated core. The bearings for supporting the motorshaft are disposed as a bearing tube in this sleeve, but outside thelaminated core.

This has the disadvantage that although the bearing tube is held in thelaminated core, the bearing is only slightly supported by the bearingtube in the radial direction, and a relatively large number of parts areadditionally needed to mount the bearing assembly.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a bearingassembly for a shaft of an electric motor, which has a simple structureand permits a good and secure support of the motor shaft, while beingeasy to mount. The object is also to provide an electric motor,including a bearing assembly, which is easy to mount and permits asecure support of the motor shaft.

An exemplary embodiment of the invention relates to a bearing assemblyfor a shaft of an electric motor, including a stator, the stator beingformed from a stator core having a large number of stator elements whichare stacked one on top of the other, the stator core comprising a firstouter partial stator core and a second outer partial stator core and acentral partial stator core, the central partial stator core beingdisposed between the two outer partial stator cores, a continuousopening being disposed in the partial stator cores, in which bearingsfor supporting the motor shaft and the motor shaft are accommodated, adiameter of the opening of the central partial stator core being smallerthan a diameter of the opening of each of the outer partial statorcores, so that a diameter transition from the central partial statorcore to an outer partial stator core forms an axial stop for a bearingin each case, a bearing being disposed in each case in the particularopening of the particular outer partial stator core. In each case, astop for one of the bearings is formed thereby, so that the positioningof the bearings and thus also the rotor shaft may be easily fixed, whilethe stator core may be easily formed and mounted. The stator elementsare also preferably designed as stator laminations.

It is also advantageous if the first outer partial stator core, thecentral partial stator core and the second outer partial stator core arestacked one on top of the other and are connected to each other. Thestator core is thus formed into a monolithic element thereby, whichsecurely holds the bearings and this also the motor shaft.

The stator core can have a first circumferential wall disposed radiallyoutside the centrally disposed opening. This wall can be used toradially hold the bearings.

The stator core can have a second circumferential wall radially outsidethe first circumferential wall, connecting webs being disposed betweenthe first circumferential wall and the second circumferential wall. Thissecond circumferential wall is used, on the one hand, to stabilize thestator core, while nevertheless permitting channels between the twocircumferential walls, which serves to cool the stator during athrough-flow.

The stator core can have radially outwardly protruding webs radiallyoutside the second circumferential wall. These webs are used toaccommodate a winding, to conduct the magnetic field, and they are alsoindirectly used for cooling purposes.

The two disposed bearings can be situated at a distance from each otherin such a way that a cavity is formed in the central partial stator corebetween the bearings in the axial direction. This cavity is formed bythe distance between the bearings with the provided diameter of theopening in the central partial stator core. This makes it possible tosave material and mass.

At least one channel can be provided in the stator core, for example, ifmultiple channels are provided, which connects or connect the cavity tothe outer chamber. This channel is advantageous so that any water thatmay have collected in the cavity may be removed or is able to flow off.Such water entering the cavity is unavoidable for applications in airconditioning systems or as a drive for a fan or for a blower, which iswhy the water must, however, be advantageously removed to avoid damage.

The channel or at least one of the channels or all channels can beintroduced into the stator elements which form the stator core. As aresult, no additional components are needed to form these channels.

The channel or at least one of the channels or all channels can beintroduced into at least one of the stator elements by means of sheetmetal cutting, sheet metal embossing or the like. This may be alreadyadvantageously integrated into the manufacturing process of the statorelements, which simplifies the manufacture.

The channel or at least one of the channels or all channels in thestator core can be oriented in the axial direction and/or in the radialdirection and/or in the circumferential direction.

At least one of the channels or a plurality of channels can be orientedin the axial direction or if at least one of the channels or a pluralityof channels is or are oriented in the radial direction. An automaticdrainage may be achieved by the design and orientation of the channels.

The particular bearing can be pressed into the openings of theparticular outer partial stator core. A more secure hold is achievedthereby.

The two outer partial stator cores can be provided with the same designand the inner partial stator core is provided with a different designtherefrom. This makes the manufacture and the parts logistics easier.

The motor shaft can be inserted, for example pressed, into the twobearings. A secure and defined positioning is achieved thereby.

The bearing assembly can be refined in such a way that at least onefirst cover is provided, which at least partially covers at least afirst bearing and the first outer partial stator core (6). The bearingcovered by the first cover may be better protected against waterthereby.

At least one second cover can be provided, which at least partiallycovers one bearing and the second outer partial stator core. The secondcover may be provided with or without the first cover. The second coveris used to better protect the bearing covered thereby against water.

At least one radial shaft sealing ring can be provided, which isdisposed in a recess of the first cover and/or the second cover and isor are provided in a sealing manner between the particular cover and themotor shaft.

The corresponding bearing, which can be disposed on the side where themotor shaft protrudes, may be protected against water thereby. Due tothe radial shaft sealing ring, a seal may be provided between the shaftand the particular cover for the purpose of preferably keeping wateraway from the bearing.

The first cover and/or the second cover can overlap the firstcircumferential wall. As a result, water is unable to have a corrosiveeffect directly in the area of the bearing at the cover, but instead theparticular cover shields the particular bearing over a wider area.

The first cover and/or the second cover can engage with at least oneopening or with multiple openings which is or are disposed radiallyoutside the first circumferential wall and/or between the firstcircumferential wall and the second circumferential wall. As a result,the first and/or second cover surrounds or surround the central area ofthe bearing assembly, possibly in an encapsulating manner, andpreferably completely encompass(es) and seal(s) this area.

The first cover and/or the second cover can be connected to the statorcore in a form-fitting manner. As a result, the sealing action ispermanently ensured.

At least one fastener can be provided on the first cover and/or on thesecond cover, with the aid of which the cover or covers is or areconnected to the stator core in a form-fitting manner. Fasteners of thistype may be, for example, pins, connecting webs or clips or the like,which are used to connect the cover or covers to each other and/or tothe stator core.

At least one fastening element is provided on one of the covers, withthe aid of which the bearing assembly may be fastened to an externalcomponent. The fastening element is preferably a fastening flange.

It is also advantageous if at least one fastening element is provided onone of the covers, which forms a receiving chamber for a control unitfor an electric motor. The fastening element may be, for example, ahousing or a housing part, which accommodates, for example, the controlunit of an electric motor.

An exemplary embodiment of the invention also relates to an electricmotor comprising a stator and a rotor, a bearing assembly according toan inventive design being formed in the stator.

Further scope of applicability of the present invention will becomeapparent from the detailed description given hereinafter. However, itshould be understood that the detailed description and specificexamples, while indicating preferred embodiments of the invention, aregiven by way of illustration only, since various changes, combinations,and modifications within the spirit and scope of the invention willbecome apparent to those skilled in the art from this detaileddescription.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description given hereinbelow and the accompanying drawingswhich are given by way of illustration only, and thus, are not limitiveof the present invention, and wherein:

FIG. 1 shows a sectional view of a bearing assembly in a stator of anelectric motor;

FIG. 2 shows another view of the bearing assembly;

FIG. 3 shows a perspective representation of the stator;

FIG. 4 shows a sectional view of an alternative bearing assembly in astator of an electric motor; and

FIG. 5 shows a sectional view of another bearing assembly in a stator ofan electric motor.

DETAILED DESCRIPTION

FIG. 1 shows a sectional view of a bearing assembly 1 in a stator 2 ofan electric motor, FIG. 2 showing an alternative view. FIG. 3 shows aperspective representation of stator 2 itself for the sake of betterunderstanding.

Bearing assembly 1 is a bearing assembly 1 for a motor shaft 3 of anelectric motor. The electric motor comprises a stator 2 and a rotor.

Stator 2 has a stator core 4, which is made up of stator elements 5stacked one on top of the other. These elements are preferably designedas stator laminations, which are stacked one on top of the other. Stator2 is preferably made up of a large number of stator elements 5, whichare stacked one on top of the other.

Stator 2 or stator core 4 is designed in such a way that it includes afirst outer partial stator core 6 and a second outer partial stator core7 and a central partial stator core 8, which are stacked one on top ofthe other. Partial stator cores 6, 7 and 8, in turn, are made up ofstator elements 5.

Central partial stator core 8 is disposed between the two outer partialstator cores 6, 7, as is apparent in FIG. 1.

A continuous opening 9, 10, 11, in which bearings 12, 13 for supportingmotor shaft 3 are arranged, is disposed in each of partial stator cores6, 7, 8. Motor shaft 3 is also disposed in bearings 12, 13 in openings9, 10, 11. Motor shaft 3 is preferably inserted, for example pressed,into the two bearings 12, 13.

Openings 9, 10, 11 have different diameters Da, Di. Diameter Da ofopenings 9, 11 of outer partial stator cores 6, 7 is at least slightlylarger than diameter Di of opening 10 of central partial stator core 8.As a result, particular stator elements 5 of central partial stator core8 form stops 14, 15 for positioning bearings 12, 13 in outer partialstator cores 6, 7.

Diameter Di of opening 10 of central partial stator core 8 is thussmaller than a diameter Da of each of openings 9, 11 of outer partialstator cores 6, 7. The diameter transition from central partial statorcore 8 to an outer partial stator core 6, 7 thus forms an axial stop 14,15 for a bearing 12, 13 in each case, so that particular bearing 12, 13may be pushed into particular opening 9, 11 up to stop 14, 15 in theaxial direction. Correspondingly, in each case, a bearing 12, 13 isdisposed in particular opening 9, 11 of particular outer partial statorcore 6, 7. Stops 14, 15 are used as a bearing seat for bearings 12, 13.

First outer partial stator core 6, central partial stator core 8 andsecond outer partial stator core 7 are stacked one on top of the otherand connected to each other. Partial stator cores 6, 7, 8 are preferablypremounted and subsequently connected to each other, outer partialstator cores 6, 7 optionally being identical parts. The two outerpartial stator cores 6, 7 thus preferably have the same design, innerpartial stator core 8, conversely, having a different design. Thisoptional embodiment of outer partial stator cores 6, 7 reduces the partcomplexity, which also lowers costs.

To dispose bearings 12, 13 in openings 9, 11, it is also advantageous ifthe latter are pressed into openings 9, 11 of particular outer partialstator core 6, 7. How far into openings 9, 11 bearings 12, 13 engagedepends on the material thickness of partial stator cores 6, 7 comparedto height h of bearings 12, 13. It is apparent in FIGS. 1 and 2 thatbearings 12, 13 protrude slightly out of openings 9, 11. The insertiondepth of bearings 12, 13 is therefore determined by height h of partialstator cores 6, 7.

It is apparent in FIG. 3 that stator core 4 has a first circumferentialwall 16 radially outside centrally disposed opening 9, 10, 11.

This wall 16 is used to arrange bearings 12, 13. Stator core 4 has asecond circumferential wall 17 radially outside first circumferentialwall 16, connecting webs 18 being disposed between first circumferentialwall 16 and second circumferential wall 17. These connecting websoptionally run radially. It is also apparent in FIG. 3 that stator core4 has radially outwardly protruding webs 19 radially outside secondcircumferential wall 17. These webs 19 are designed to be connectedradially on the outside to elements 20 running in the circumferentialdirection. Elements 20 form a circumferential, segmented wall, which isinterrupted multiple times.

It is also apparent in FIG. 1 that the two arranged bearings 12, 13 aresituated at a distance from each other in such a way that a cavity 21 isformed in the radial direction between bearings 12, 13 in opening 10 ofcentral partial stator core 8. Cavity 21 is delimited at the top andbottom by bearings 12, 13. Cavity 21 is delimited radially on the insideby the shaft and cavity 21 is delimited radially on the outside by thecentral partial stator core. Water may possibly enter this cavity 21during the operation of the electric motor.

To permit a drainage of cavity 21, at least one channel 22 is providedin stator core 4, preferably multiple channels 22 are provided, whichconnects or connect cavity 21 to outer chamber 23.

It is particularly advantageous if channel 22 or at least one ofchannels 22 or all channels 22 is/are introduced into stator elements 5,which form stator core 4. This avoids using bearings 12, 13 for theoutflow of water or the water not being able to exit. Channel 22 or atleast one of channels 22 or all channels 22 may be introduced into atleast one of stator elements 5 by means of sheet metal cutting, sheetmetal embossing or the like. This method is preferred because it may beintegrated into the manufacturing method of stator elements 5, such asthe stator laminations.

It is advantageous if channel 22 or at least one of channels 22 or allchannels 22 in stator core 4 is/are oriented in the axial directionand/or in the radial direction and/or in the circumferential direction.It is also advantageous if at least one of channels 22 or a plurality ofchannels 22 is or are oriented in the axial direction or if at least oneof channels 22 or a plurality of channels 22 is or are oriented in theradial direction. FIG. 1 shows that channels 22 are oriented in theradial direction.

The bearing assembly illustrated in FIGS. 1 through 3 is preferably partof an electric motor, which comprises a stator and a rotor. The motoris, for example, a DC motor or a BLDC electric motor.

Partial stator cores 6, 7, 8 are manufactured separately from each otherduring manufacture and are then joined together and connected to eachother in a subsequent production step. A winding may then be mounted.

It is furthermore apparent in FIG. 1 that motor shaft 3 is pushed intobearings 12, 13 from above all the way to the stop and is secured on theopposite side, i.e. at the bottom, with the aid of a securing ring 24 sothat motor shaft 3 is unable to slip out of bearings 12, 13. As aresult, motor shaft 3 has only a slight vertical axial clearance, whichis determined by the axial clearance of bearings 12, 13.

FIGS. 4 and 5 each show another sectional view of an alternative bearingassembly 1 in a stator 2 of an electric motor, the alternative bearingassemblies in FIGS. 4 and 5 building upon bearing assembly 1 in FIG. 1and each having additional covers for protection against water.Accordingly, reference is hereby made essentially entirely to thedescription of bearing assembly 1 described above.

To protect bearings 12, 13, bearing assembly 1 in FIGS. 4 and 5 has atleast one first cover 100, which at least partially covers bearing 13and first outer partial stator core 6. First cover 100 protects bearing13 against water.

Alternatively or additionally, a second cover 101 is provided, which atleast partially covers bearing 12 and second outer partial stator core7.

In the area of motor shaft 3, at least cover 100 has a central recess102, such as an opening, at least one radial shaft sealing ring 103being provided, which is disposed in recess 102 of first cover 100 andis accommodated in a sealing manner between first cover 100 and motorshaft 3. FIG. 4 and FIG. 5, respectively, show only one radial shaftsealing ring in a recess of cover 100. Alternatively or additionally, arecess and a radial shaft sealing ring may also be provided in secondcover 101 between the second cover and the motor shaft.

FIGS. 4 and 5 also show that first cover 100 and second cover 101overlap first circumferential wall 16. Alternatively only first cover100 or only second cover 101 may overlap first circumferential wall 16.First cover 100 and second cover 101 engage with at least one opening104 or with multiple openings 104, which is or are disposed radiallyoutside first circumferential wall 16 and/or between firstcircumferential wall 16 and second circumferential wall 17.Alternatively, only first cover 100 or only second cover 101 may engagewith the at least one opening 104 or with multiple openings 104.

It is particularly advantageous if first cover 100 and/or second cover101 is or are connected to stator core 4 in a form-fitting manner. Theform-fitting connection may take place in that first cover 100 or secondcover 101 is connected directly to stator core 4 or that first cover 100is connected to second cover 101 and stator core 4 is encompassed bycovers 100, 101 thereby, so that covers 100, 101 are indirectlyconnected to the stator core.

For fastening purposes, fastener(s) 105 is or are preferably provided onfirst cover 100 and/or on second cover 101, with the aid of which coveror covers 100, 101 is or are connected to stator core 4 in aform-fitting manner. Fastener 105 may be designed as a pin, connectingwebs or the like for the purpose of fastening stator core 4 or the onecover 100, 101 to the other cover 101, 100. The one cover 100, 101 maythus protrude through the stator core, in particular through openings104, where it may be connected to the particular other cover 101, 100.Fastener 105 of this type are preferably fastened to particular cover100, 101 by means of injection molding or form a single piece therewithor are molded thereon. The connection between fastener 105 and theparticular cover may also take place by means of ultrasonic welding. Inparticular, fastener 105 may be injection-molded onto the one cover 100,101 and be connected to the other cover 101, 100 with the aid ofultrasonic welding.

It is advantageous if one of covers 100, 101 or both covers 100, 101 aremade from plastic. It is advantageous if fasteners 105 are also madefrom plastic.

FIGS. 4 and 5 show that first cover 100 abuts the outer race of bearing13. Second cover 101 also abuts the outer race of second bearing 12. Asa result, the particular cover is designed or disposed to berotationally fixed with respect to stator core 4.

If channels 22, such as water drainage bores, are provided in statorcore 4, they advantageously run between fastener 105, such as pins,connecting webs or the like.

FIG. 5 shows that at least one fastening element 106, such as a flange,is provided on one of covers 101, with the aid of which the bearingassembly may be fastened to an external component.

Alternatively or additionally, at least one fastening element 106 may beprovided on one of covers 100, 101, which forms a receiving chamber fora control unit for the electric motor.

FIG. 5 shows that cover 101, together with fastening element 106, isguided into or through stator core 4 from below.

The invention being thus described, it will be obvious that the same maybe varied in many ways. Such variations are not to be regarded as adeparture from the spirit and scope of the invention, and all suchmodifications as would be obvious to one skilled in the art are to beincluded within the scope of the following claims.

What is claimed is:
 1. A bearing assembly for a motor shaft of anelectric motor, the bearing assembly comprising: a stator formed from astator core made up of a plurality of stator elements that are stackedone on top of the other, the stator core having a first outer partialstator core and a second outer partial stator core and a central partialstator core, the central partial stator core being disposed between thetwo outer partial stator cores; and a continuous opening disposed in thepartial stator cores, in which bearings for supporting the motor shaftand in which the motor shaft are accommodated, wherein a diameter of theopening of the central partial stator core is smaller than a diameter ofthe opening of each of the outer partial stator cores so that a diametertransition from the central partial stator core to an outer partialstator core forms an axial stop for a bearing, the bearing beingdisposed in each case in a particular opening of a particular outerpartial stator core.
 2. The bearing assembly according to claim 1,wherein the first outer partial stator core, the central partial statorcore, and the second outer partial stator core are stacked one on top ofthe other and are connected to each other.
 3. The bearing assemblyaccording to claim 1, wherein the stator core has a firstcircumferential wall disposed radially outside the centrally disposedopening.
 4. The bearing assembly according to claim 3, wherein thestator core has a second circumferential wall disposed radially outsidethe first circumferential wall, and wherein connecting webs are disposedbetween the first circumferential wall and the second circumferentialwall.
 5. The bearing assembly according to claim 4, wherein the statorcore has radially outwardly protruding webs disposed radially outsidesecond circumferential wall.
 6. The bearing assembly according to claim1, wherein the two arranged bearings are situated at a distance fromeach other such that a cavity is formed in the axial direction betweenthe bearings in the opening of the central partial stator core.
 7. Thebearing assembly according to claim 6, wherein at least one channel isprovided in the stator core or wherein a plurality of channels areprovided to connect the cavity to the outer chamber.
 8. The bearingassembly according to claim 7, wherein the channel or at least one ofthe channels or all channels are introduced into the stator elements,which form the stator core (4).
 9. The bearing assembly according toclaim 8, wherein the channel or at least one of the channels or allchannels are introduced into at least one of the stator elements viasheet metal cutting or sheet metal embossing.
 10. The bearing assemblyaccording to claim 8, wherein the channel or at least one of thechannels or all channels in the stator core are oriented in the axialdirection and/or in the radial direction and/or in the circumferentialdirection.
 11. The bearing assembly according to claim 8, wherein atleast one of the channels or a plurality of channels are oriented in theaxial direction or at least one of channels or a plurality of channelsare oriented in the radial direction.
 12. The bearing assembly accordingto claim 1, wherein the bearing is pressed into the opening of the outerpartial stator core.
 13. The bearing assembly according to claim 1,wherein the two outer partial stator cores have a substantially samedesign, and wherein the inner partial stator core has a different designtherefrom.
 14. The bearing assembly according to claim 1, wherein themotor shaft is inserted, or pressed into the two bearings.
 15. Thebearing assembly according to claim 1, wherein at least one first coveris provided, which at least partially covers the bearing and the firstouter partial stator core.
 16. The bearing assembly according to claim1, wherein at least one second cover is provided, which at leastpartially covers the bearing and the second outer partial stator core.17. The bearing assembly according to claim 1, wherein at least oneradial shaft sealing ring is provided, which is disposed in a recess ofthe first cover and/or the second cover and is provided in a sealingmanner between the particular cover and the motor shaft.
 18. The bearingassembly according to claim 15, wherein the first cover or the secondcover overlaps the first circumferential wall.
 19. The bearing assemblyaccording to claim 15, wherein the first cover and/or the second coverengages with at least one opening or with multiple openings, which aredisposed radially outside the first circumferential wall and/or betweenthe first circumferential wall and the second circumferential wall. 20.The bearing assembly according to claim 15, wherein the first coverand/or the second cover is or are connected to the stator core in aform-fitting manner.
 21. The bearing assembly according to claim 20,wherein a fastener is provided on the first cover and/or on the secondcover, with the aid of which the first or second cover is connected tothe stator core in a form-fitting manner.
 22. The bearing assemblyaccording to claim 15, wherein at least one fastener is provided on oneof the covers, with the aid of which the bearing assembly is adapted tobe fastened to an external component.
 23. The bearing assembly accordingto claim 15, wherein at least one fastening is provided on one of thecovers, which forms a receiving chamber for a control unit for anelectric motor.
 24. An electric motor comprising a stator and a rotor,the stator forming a bearing assembly according to claim 1.